Blanket feed binder applicator

ABSTRACT

A binder applicator for applying liquid binder to textile fibers is described which involves a roller having a slightly concave surface from end to end. The roller is provided at each end with a rim to direct binder towards the center of the roller surface. The applicator housing is provided with an inlet to direct binder into the housing and an outlet for the removal of binder, the outlet means being adjustable in height inside the applicator housing to maintain a liquid depth in the housing sufficient to insure that the roller passes through the liquid during rotation to maintain binder on the surface of the roller.

United States Patent [191 Schweppe Nov. 19, 1974 [54] BLANKET FEED BINDER APPLICATOR 3,714,927 2/1973 Krogel 118/234 X 75 In to ohn V. Schwe e Shelb N.C. 1 van r J pp y Primary Examiner-John P. McIntosh [73] Assignee: PPG Industries, Inc., Pittsburgh, Pa. Attorney, Agent, or i h E C l [22] Filed: Dec. 29, 1972 211 App]. No.: 319,423 [57] ABSTRACT A binder applicator for applying liquid binder to textile fibers is described which involves a roller having a 2? E8 118/234 1 18/259 1 343 732 slightly concave surface from end to end. The roller is d E 20 provided at each end with a rim to direct binder to- 1 0 care Ilia/DI wards the center of the roller surface. The applicator housing is provided with an inlet to direct binder into 56 R f d the housing and an outlet for the removal of binder, 1 t e the outlet means being adjustable in height inside the UNITED STATES PATENTS applicator housing to maintain a liquid depth in the 1,397,522 11/1921 Jacobs 118/260 housing sufficient to insure that the roller passes 2.3319 9 3 Hoffma et a1 118/234 through the liquid during rotation to maintain binder X on the urface of the roller 2,728,972 l/l956 Drummond et al ll8/DIG. 20 3,589,332 6/1971 Dinse 1 18/234 X 4 Claims, 3 Drawing Figures l BLANKET FEED BINDER APPLICATOR BACKGROUND OF THE INVENTION In the textile art it is conventional to apply various coatings to textile yarns to assist in processing textile yarns in various physical and chemical operations such as twisting, weaving, dyeing and the like. In the preparation of fiber glass textiles it is also common to apply special coatings such as sizes to the glass fiber filaments as they are being formed to permit rapid winding of the filaments typically as strands on forming packages for subsequent processing.

Various methods and types of apparatus have been used to apply coatings, binder and sizes to textile yarns and fibers in the past. Thus in preparing glass fiber filaments, for example, it has been conventional to pass the filaments as they are pulled from asource of molten glass over the surface of a free rolling applicator or pad which is immersed in sizing fluid to apply sizing to the filaments. The filaments are then joined together physically into one or more strands using a gathering shoe and wound on a forming package associated with a mandrel turned by a suitable motor. This process of attenuating glass fibers from a molten glass source, coating the fibers, forming strand and winding the resulting strand is illustrated in U.S. Pat. No. 3,652,243. In other operations glass fibers being attenuated from a molten glass source have been sprayed with binders and sizes during attenuation. An operation of this character is illustrated in U.S. Pat. No. 3,490,707.

Various difficulties are encountered utilizing the systems of the prior art employed to apply binders, sizes, coatings and the like to textiles and particularly to glass fibers during formation. Thus, applicators of the roller type shown in the aforementioned U.S. Pat. No. 3,652,243 often apply binder in a nonuniform manner due to their generally flat surfaces. The flooding of these surfaces to insure uniformity by maintaining the applicator housing filled with liquid results in considerable spilling of binder out of the applicator and down the winder chutes which wastes binder and causes considerable difficulty in maintaining the winder areas clean. Sprays often result in uneven coating of fibers being attenuated, create considerable humidity in the applicator area and result in considerable waste of binder or size solutions.

THE PRESENT INVENTION In accordance with the present invention an improved sizing or binder applicator is provided which overcomes many of the shortcomings of the prior art. Thus the applicator of the instant invention provides an applicator surface which is concave in shape and provides from the ends to the center a gentle, but definite slope to urge the fibers in contact with it to converge and provides for the flow of size or binder toward the center of the applicator surface. Binder is prevented from escaping at the side portions of the applicator roll by shoulders provided at each side of the applicator roll which cooperate with the sloped surface to maintain maximum size and binder buildup toward the mid portion of the applicator surface. The housing for the applicator roll is provided with an inlet and outlet for the continuous feed of solutions to the applicator roll and level control is provided in the housing to maintain solution levels in the housing at a point where spilling of binder out of the housing is avoided. Binder or size solutions removed from the housing may be recirculated to the feed inlet, thus eliminating size or binder solution waste. Baffle means are also provided to assist in the flow of binder or size solutions to the housing or onto the surface of the applicator roll as desired.

For a more complete description of the present invention, reference is made to the drawings, in which:

FIG. 1 is a side elevation of the applicator of the instant invention with one baffle configuration shown;

FIG. 2 is a front elevation of the applicator of FIG. 1; and

FIG. 3 is a side elevation of the applicator of FIG. 1 with a second baffle configuration.

Turning to the drawings and FIGS. 1 and 2 in particular, there is shown an applicator roll 1 contained in housing 3 and freely rotatable therein on a shaft 2 which is mounted in bushings 14 and 15. Housing 3 is provided with an inlet 4 and an outlet 5. Located below the inlet 4 and secured to the wall of housing 3 is a baffie plate 6 which traverses the width of the roll 1 and directs fluid entering inlet 4 to the interior of the housing 3 and onto the surface of the applicator roll 1. Housing 3 is provided with a neck portion 7 through which the outlet 5 passes. A set screw 9 passes through a collar 8 provided at the bottom of the neck 7 of housing 3. The collar 8 is provided with a channel 10 which permits the insertion of the outlet 5 therethrough to any desired distance into the housing 3. vertical movement of the outlet pipe 5 is of course limited in an upward direction by the roll 1. Once the outlet 5 is in the desired position with its tip at the level at which liquid contained in housing 3 is to be maintained, set screw 9 is tightened to maintain the top of the outlet at this level. Housing 3 is provided with an aperture or port 17 through which the roll 1 protrudes so that it can be contacted by the textile fiber or strand to be coated.

The surface of the roller applicator 1 is generally sloped from the sides to the center as shown more clearly in FIG. 2. As seen therein the roll 1 is provided with collars 11 and 12 on either side of the roll 1. While for illustrative purposes, collars 11 and 12 appear as separate pieces, the roll 1 can be formed of an integral piece having collars provided at each side. In FIG. 2 the slope of the applicator surface from the collars 11 and 12 to the center has been exaggerated for illustrative purposes. In general the concavity of the applicator surface is typically from about 0.003 to about 0.015 inch on the radius based on a 4 inch wide applicator roll and a concavity of this order has been found to be particularly effective in applying sizes and binders to fan-shaped glass fibers drawn across the applicator surface. Thus, the concavity of the surface of roller 1 is such that binder is directed and concentrated on the V-shaped fan of glass fibers 16 being drawn over the surface of the roller 1 for maximum application and lubrication of these fibers 16. With fans of fibers l6 traveling at the high speeds encountered during forming, 7,000 to 20,000 feet per minute, typically 9,000 to 12,000 feet per minute, this design affords ample assurance that the fibers are uniformly and completely coated as they pass over the surface.

In the embodiment shown in FIGS. 1 and 2, the binder, size or coating solutions to be applied to the fibers 16 passing over the surface of roll 1 are directed into the housing 3 through inlet 4 and onto the surface of the baffle member 6 from which they flow onto and across the sump face of the roller 1 in a thin film-like sheet of fluid. The excess fluid accumulates in the chamber of the housing 3 until the level of fluid or solution reaches the top of the outlet member 5. The opening in the outlet permits the flow of excess solution out of the chamber 3 to a collection zone from which it may be returned to the inlet 4 by suitable piping and pumping means not shown. It is of course understood in this arrangement that a level of liquid is maintained in housing 3 such that the roll 1 during rotation dips into the solution and carries it on its surface through the housing 3 to the point of contact with fluid passing over baffle 6 and ultimately the fluid contacts the fibers 16 at the opening 17 provided in the front of housing 3 In the embodiment shown in FIG. 3, a baffle member 6a is provided which provides the feed of solutions to the applicator roll 1 in a manner different than FIG. 1. Thus, as shown in FIG. 3, the fluid or solution entering the inlet 4 is distributed over a baffle 6a which terminates at a point slightly above the surface of the applicator roll 1. This directs a sheet or blanket of solution onto the surface of the applicator roll, preferably on a continuous basis. The solution on the roll is then carried into the opening 17 of the housing 3 where it contacts the fibers 16 being drawn across the surface thereof. Solution remaining on the roll 1 after contact with the fibers then enters the interior of housing 3. In this embodiment, a level of solution can still be maintained in housing 3 at a level sufficient to insure that the applicator roll must pass therethrough to insure that the surface of roll 1 is constantly and thoroughly wetted. In a second mode of operation it is also possible to drop the top of outlet to the lower end of the neck 7 and continuously remove solution falling off the surface of the roll 1 during its passage through housing 3. In this manner a blanket of solution is constantly presented to the surface of the roll 1 for application to the fibers 16 with excess solution being removed continuously from the housing 3. This type system of continuous feed and withdrawal without fluid accumulation in housing 3 can be practiced with the embodiment of FIG. 1.

In general the construction of the instant applicator involved the use of conventional materials. Thus, the housing, tubing, baffles and other structural units disclosed may be constructed of metal, ceramics, rigid plastics and the like. The applicator roll may be constructed ofmetal, hard rubber or other like material. In the preferred embodiment of the invention the applicator roll is constructed of graphite and the housing and related tubing of stainless steel.

Typical of the solutions which are applied to the surface of the roller applicator of the instant invention are sizes such as described in U.S. Pat. No. 3,227,192 and U.S. Pat. No. 2,951,782. These solutions as well as solutions containing binders and coatings compatible with the textile fibers to be treated with the applicator, and in particular with glass fibers may be used with the applicator of this invention.

As will be readily appreciated by utilizing the instant invention a fan of textile fibers such as glass fibers can be readily coated with solutions of textile size, binder and the like in an efficient manner with minimized waste of binder solution. The applicator lends itself to sizing operations where metered quantities of solution can be applied to the applicator surface and continuously removed from the applicator housing during the coating or sizing operation. Further, the concave surface of the roller and the collars provided concentrate the solutions applied to the roller surface toward the central area of the roller surface where the fan of fibers conventionally tend to converge during a glass fiber forming sizing operation. In lieu of the neck portion 7 of housing 3 being provided, and in which fibers and other debris tend to accumulate during operation, the bottom of housing 3 can be cut straight across thereby reducing the volume of the sump area.

While the invention has been described with reference to certain specific illustrative embodiments, it is not intended that it be limited thereby except insofar as appears in the accompanying claims.

I claim:

1. A roller applicator for applying solution to fibers drawn across the surface thereof comprising a housing, a freely rotatable cylindrical applicator contained in said housing, said housing being provided with a port through which the roller is exposed to the atmosphere and out of which a portion of the surface of the applicator protrudes; means to feed the solution across the surface of the roller inside of said housing; means to remove excess solution from the housing continuously; means associated with the applicator surface to direct flow of solution on the surface of said roller towards the center thereof and away from the ends thereof, said means including a concave applicator surface and collar means on each end of said applicator, said collars having diameters greater than the diameter of any portion of the applicator located therebetween, to thereby direct fluid from said collar towards the center of said applicator along said concave surface.

2. The apparatus of claim 1 wherein baffle means are provided across the width of the applicator and adjacent its surface to provide a blanket of fluid on the surface continuously when the roller is rotating and fluid is being fed to the baffle surface on a continuous basis.

3. The apparatus of claim 1 wherein fluid fed to the housing is contacted with a baffle directing the fluid away from the surface of the roller applicator and wherein fluid level control means in the housing is at a level such that the roller applicator is at least partially in contact with solution in the housing at all times during operation.

4. An applicator system for applying solution to fibers passed in contact with the surface thereof comprising a housing, fluid inlet means communicating with the interior of said housing, a cylindrical roller applicator positioned in said housing and freely rotatable therein, adjustable liquid level control means in said housing to limit the depth of fluid contained therein, means on the surface of said roller applicator including a concave applicator surface and a collar on each end of said applicator, said collars being greater in diameter than the diameter of any portion of the applicator located therebetween to thereby direct fluid contacted with the surface of said applicator towards the central portion of said surface of the applicator and away from the collars. 

1. A roller applicator for applying solution to fibers drawn across the surface thereof comprising a housing, a freely rotatable cylindrical applicator contained in said housing, said housing being provided with a port through which the roller is exposed to the atmosphere and out of which a portion of the surface of the applicator protrudes; means to feed the solution across the surface of the roller inside of said housing; means to remove excess solution from the housing continuously; means associated with the applicator surface to direct flow of solution on the surface of said roller towards the center thereof and away from the ends thereof, said means including a concave applicator surface and collar means on each end of said applicator, said collars having diameters greater than the diameter of any portion of the applicator located therebetween, to thereby direct fluid from said collar towards the center of said applicator along said concave surface.
 2. The apparatus of claim 1 wherein baffle means are provided across the width of the applicator and adjacent its surface to provide a blanket of fluid on the surface continuously when the roller is rotating and fluid is being fed to the baffle surface on a continuous basis.
 3. The apparatus of claim 1 wherein fluid fed to the housing is contacted with a baffle directing the fluid away from the surface of the roller applicator and wherein fluid level control means in the housing is at a level such that the roller applicator is at least partially in contact with solution in the housing at all times during operation.
 4. An applicator system for applying solution to fibers passed in contact with the surface thereof comprising a housing, fluid inlet means communicating with the interior of said housing, a cylindrical roller applicator positioned in said housing and freely rotatable therein, adjustable liquid level control means in said housing to limit the depth of fluid contained therein, means on the surface of said roller applicator including a concave applicator surface and a collar on each end of said applicator, said collars being greater in diameter than the diameter of any portion of the applicator located therebetween to thereby direct fluid contacted with the surface of said applicator towards the central portion of said surface of the applicator and away from the collars. 